Form for molding concrete structures



Nov. 19 1935. T, THQRN 2,021,210

FORM FOR MOLDING CONCRETE STRUCTURES Filed Oct. 16, 1953 4 Sheets-Sheet l fwd/ apse Z7}- orp- Nov. 19, 1935. T THORN FORM FOR MOLDING CONCRETE STRUCTURES Filed Oct. 16, 1933 4 Sheets-Sheet 2 Nov. 19, 1935. T. THORN FORM FOR MOLDING CONCRETE STRUCTURES Filed Oct. 16, 1953 4 Sheets-Sheet 3 Int/v70? lalarepcefaarp W m Nov. 19, 1935. L THORN 2,021,210

FORM FOR MOLDING CONCRETE STRUCTURES Filed Oct. 16, 1933 4 Sheets-Sheet 4 Patented Nov. 19, 1935 UNITED STATES PATENT OFFICE FORM FOR MOLDING CONCRETE STRUCTURES 10 Claims.

This invention relates to forms and methods for forming concrete structures and is particularly directed to such means for, and methods of, constructing elongated structures of varying dimensions and patterns, such for instance as the guardrails of concrete bridges, which structures require careful adjustment to preserve accurate alignment longitudinally, to adjust for vertical lines on grades and to adjust for varying spacing of parts incident to variations in span length or the like.

In building concrete bridges, more and more attention is being paid to the design, alignment and finish of the guard rails lying at the side edges of the structure. At the ends of the bridge, posts are placed and in structures of any considerable length the intermediate space between these posts is divided into panels marked off by additional posts and at times by sub-posts of lesser size. Lying along the surface of the ridge between these posts, and usually either integral with or securely attached to the floor surface of the bridge, are longitudinal beams constituting Wheel guards and spaced above these lower beams are beams usually designated hand rails. It is of extreme importance in a structure intended to be permanent as these concrete bridges are, that these rails be accurately aligned longitudinally and this is particularly true of the top rail, the alignment of which intrudes itself upon the vision of the users of the bridge, as they approach and cross. The space between the upper and lower rails is paneled, in most cases this being effected by small posts or spindles spaced apart and great care must be taken that these spindles are vertically disposed whether th bridge be level or on a grade.

adjustably securing the mold parts together;

To provide means for adjusting the dimensions of the rails;

To provide means for varying the spacing of the upper or hand rail from the lower or wheel rail;

To provide means for varying the dimension and spacing of the spindles; v

To provide means for vertically aligning the spindles; and

To provide such a mold structure which will be easily removable without destruction of the usually green and therefore insufficiently hardened concrete.

The means by which the foregoing and. other objects are accomplished and the manner of their accomplishment will readily be seen from the following specification byreference to the accompanying drawings, in WhlChZ' Fig. 1 is a vertical sectional elevation of the forms with concrete in place, taken as on the line II of Fig. 3, and on a substantially larger scale than Fig. 3.

Fig. 1A is a much enlarged fragmentary detail showing attachment of a stringer to a stud.

Fig. 2 is a fragmentary sectional elevation taken as on the line II.II of Fig. Band on the same scale as Fig. 1.

Fig. 3 is a side elevation of the forms, a portion of the panel being broken away, and a fragmentary portion of a second panel being shown in section taken substantially along the longitudinal center line.

Fig. 4 is a sectional elevation of a fragmentary portion of one of the side forms adjacent to and including a sub-post portion. 7

Fig. 5 is a horizontal section taken as on the line V-V of Fig. 4 with two opposed forms shown assembled.

Fig. 6 is a fragmentary vertical section taken as on the line VIVI of Fig. 5.

Fig. 7 is a fragmentary sectional elevation, taken as on the longitudinal center line of the forms, of a modified form of spindle forming molds for a panel, a portion of the panel being broken away.

Figs. 8. and 9 are vertical sectional elevations of fragmentary portions of a panel similar to Fig. 7, showing modifications of the spindle design.

Fig. 1 0 is a fragmentary horizontal section taken as on the line X--X of Fig. 7.

Fig. 11 is a fragmentary vertical section on an enlarged scale of the lower end of one of the spindle molds shown in Fig. 7.

Fig. 12 is a fragmentary sectional elevation, on an enlarged scale taken as on the line 1-1 of Fig. 3, showing a modification of the means for adjusting at a sub-post.

Fig. 13 is a fragmentary section of a portion of one of the form members taken as onthe line XIII-XIII of Fig. 12. s

Fig. 14 is a fragmentary sectional plan taken of similar shape in the finishedcon'crete.

as on the line XIV-XIV of Figs. 15 and 16 with a locking key in place.

Fig. 15 is a fragmentary portion of one of the form members on an enlarged scale showing the conformation of the slot therein.

Fig. 16 is a fragmentary sectional elevation taken as on the line XVI-XVI of Fig. 14 showing the locking key and securing Wedge in place.

Fig. 17 is a face view of an end plate on the same scale as Fig. 1 taken as on theline XVII XVII of Figs. 3 and 19.

a Fig. 18 is a plan view of the same plate.

Fig. 19 is a vertical elevation thereof. 7

Referring now to the drawings in which the various parts are indicated by numerals, the form is made up of two, usually identical, independent halves. Each of these halves has a frame structure comprising upper and lower longitudinal stringers iii and l 1 respectively, preferably of angle iron, the lower of which stringers H is rigidly secured to a number 'of vertically disposed studs 12, preferably as by welding. These studs usually'of channel iron preferably are uniformly spacedthroughout the length of the frame except that where a frame covers more than one panel, a variation in spacing often occurs atthe subpost. The stringer h? is provided adjacent each stud with a bracket 53, ordinarily short lengths of angle iron, which bracket is secured to the stringer preferably as by welding. Each stud is provided Witha plurality of vertically disposed slots f t and the brackets areprovided with complementary slots 13A, wherebythe brackets may be secured to the studs as by bolts 15, this method of attachment providing for vertical adjustment of the brackets and of the stringer to which they are attached. The stringer it] may rest directly against the stud 12, in which case the leg portion IEJA of the stringer will be at right angles to the stud, and horizontal, but it is preferable, a's'shown in'Fig. 1A, to place between the stringer I and the stu'd a wedge shaped filler 16, which may 7 capped by a longitudinal member I1 and the lower ends rest on a similar longitudinal member or sill, 13, to both of which longitudinal members they are secured, preferably as by welding.

I9 is a vertically disposed plate which extends substantially the length of the frame and is the side form for one side of the upper or hand rail Preferably the upper edge of the plate 19 is stiffened by a coextensive angle member 2|, and its lower edge is stifiened by a channel shaped member "22, which extends inward toward the concrete should it be desired to form a rabbet Secured to the plate 59, preferably as by welding,

and spaced to conform to the spacing of thestuds 12 are angle iron brackets 23. Thesebracketsare provided with horizontally disposed slots 24 and the studs with complementary vertical slots 25,

through which bolts, purposely, for the purpose of-clearness not shown, may be passed to secure thebrackets to the studs. The vertical slots in the studs permit vertical adjustment and the horizontal studs in the brackets permit horizontal alignment, both with respect to the frame.

"tinuously past such sub-posts.

blocks 3| are used if necessary to bring the align 1Q ing screws below the flanges of the cap. 32

'is a vertically'disposed plate, coextensive with and also forming part of the frame, which is secured to the lower portionof the studs I2 as a side form for one side of the bottom rail 33. 15 The upper edges of these rails being ordinarily beveled, the upper portion 34 of the plate 32 is preferably bent inward on a corresponding bevel. 35 is an angle iron secured to the studs l2 and reinforcing the inwardly turned portion 34 of 20 the plate.

The form half thus constructed, comprises-an integral frame having the form plate forthe lower rail integrally attached and the form plate and other form members for the top rail ad- 25 justably secured. Twoof thesehalvesare aligned and spaced apart to constitute the main portions of the form for the guard of abridge.

The vertical jwebsof themembers 10 and II are provided, preferably at "closely and equallygo spaced intervals with slots 36, 31 respectively which are adapted to receive transverse 'tie bars 38, 39. These tie bars extendfromslotsinthe members it and H of one side frame "to slots in the corresponding members H1 and 1| of the other side frame and are themselves provided with slots '40 adapted to receive'locking keys 4|, Z which keys engage against the outer surfaces of the members l9 and I l to prevent the form from spreading apart, these keys being 'of usual "taper 40 '01- wedge shape.

In Figs. 15, 16 and 17 a special form 'ofslot 40A and of notched key 41A is shown, the enlarged portion of the slot being adapted'to receive an ordinary wrought nail 42 as a tightening wedge. 45

The upper tie bars '38 also serve as 'supportsfor spacer blocks 43 and plates 44, supported' by such blocks, which form the underside of the top'rail between the spindles 45. V

The ends of the concrete rails both top and "50 bottom may abut solidly against :the main posts '46 (Fig. 3) used in connection *therewithbut usually at one end, if not at both ends,'theyare spaced therefrom to: provide. for'expans'ion. 'In such case end'plates 41, 48 areused to make thegg end form for the rails. A typical plate 48 is shown in Figs. 1'7, 18 and 19. This plate hassecured thereto a transverse strap 49 having 'ends 50 bent at right angles, which ends are adapted to be secured to thestringers H as by bolts 5!.00

Otherwise the plates may be braced from the posts 46 in any usual or desired "manner.

Where sub-posts such as the post 20A, 'Fig. 1,

occur, that-is posts which do not require an enlargement of the rai1s,"the frames extendcongg The sides o'f the posts in such case are formed of plates 52, each having an outwardly turned'flange 53 at the bottom, which flange rests on "the upper'surfaceof the angle 35 and/or the inclined portion 34 of m the lower sideplate 32, and an outwardly'fianged portion 5'4: whichunderlies and closely abuts the horizontal leg of the framemember I0. 55 is a panel form of desired configuration secured to the plate 52.

This panel may be integrally secured, as by welding, or may be secured by bolts 56 such as shown in Fig. which pass through slots 56A Fig. 5, allowing horizontal movement. Adjacent the side edges of the plates 52, are end retaining strips 51 which are secured at their upper and lower ends as by bolts 58. These bolts pass through the strips 52 and through horizontally disposed slots 59 by means of which the upper and/or lower ends of each strip may be shifted to vertically position the strip, as for instance when the bridge and the railings are on a grade. Disposed between the plates 53 are removable end plates 60. Each of these end plates has secured to its side edges, as by welding, channel shaped members 6| having outwardly turned flanges 62, the groove lying between the flanges being adapted to receive the strip 5'5 whereby when the strips 51 are adjusted to a vertical position and the end plates 60 are disposed between the side plates 52 and engaged with the strips a completely closed column form is made. The groove in a standard channel being ordinarily flaring, the strips 52 are preferably also so shaped. Preferably the lower ends of the plates 65 are provided with outwardly turned flange portions 63, which flange portions extend substantially to the adjacent spindles and prevent upward flow of concrete in the lower rails at such place. Secured to, and projecting outward from, the plates 52 are bolts 64 which extend through the slots 36, 31 in the stringers Hi and II respectively. Each of these bolts is provided with nuts 65, 66 on opposite sides of these stringers by means of which bolts the plates are supported solidly with respect to such stringers, and also by means of which adjustment of these plates particularly at the upper ends thereof may be had relatively to the stringers.

It occurs at times that positioning of the bolts 65 and of the slots 36, 31 in the stringers l6 and H do not conform, in such case a modification shown in Figs. 12 and 13 is made use of. In this modification an angle iron 10 is secured to the plate 52, this angle iron having a vertically disposed slotted leg H. Adjusting bolts 12 connect this angle with the stringer H (or Iii as the case may be), the slots in the legs ll of the angle permitting attachment at any desired point.

If desired two or more frames may be clamped together to secure a desired length of frame. In such case the end stud [2 of one frame is abutted against the end stud I2 of a second frame, as shown in Fig. 14;, and key MA inserted in the slots 40A. The keys MA are .notched, as shown in Fig. 15, to engage the abutting webs of the studs and a suitable wedge, such as the nail 42, is driven in to wedge the web tightly in place and complete the engagement.

The foregoing description has been confined largely to forms for the construction of hand rails making use of precast spindles. In Figures '7 to 11 inclusive, forms are illustrated for pouring the rails and spindles integrally. In such case the side plates 52A of the sub-posts are substantially coextensive with the frames. Disposed between these side plates are removable form members each occupying the space between a pair of adjacent spindles. Each of these form members comprises a pair of vertically disposed plates 12, adapted to extend from one side plate 52A to the opposite one thereof. At the top these plates are connected by an integral plate, which may be a flat plate 13 as shown in Fig. '7, of gothic archform 13A as shown in Fig. 8, twoupwardly extending plates 133 as shown in Fig. 9, or such other configuration as may be desired. The lower portion of each side plate 12 has a short section 14 hingedly connected thereto. The lower end 15 of each of these short sections is bent :5 inward at right angles, the length of the inwardly ,bent portions being one-half the distance between the vertical portions. Complementary hasp and staple locking members Ti and 1s secured to the sections 75 are used to hold the sections in working position. If desired to bevel the edges of the spindles, suitably shaped and disposed blocks 19 are secured to the plates 52A. Also secured to the plates 52A are blocks 86 which are spaced from the blocks 19 to form grooves 8! 5 adapted to receive the edges of the plates 12. Should the spindle edges not be beveled, positioning channels corresponding to the channels 6| Fig. 5 may be secured to the plates 12, in lieu of the blocks 80 and complementary strips, cor- 20 responding to the strips 59, be secured to the plates 52A.

In these types, opposed plates 52A are assembled with the above described form members or cores, therebetween, and are clamped together, by ties and wedges as before. To permit insertion of the ties the plates 52A, are provided with slots 36A lying within the cores and aligning with slots 36 in the stringers H], II.

In making use of the forms hereinbefore described for building the guard rails of concrete bridges, the bridge floor is completed, preferably leaving reinforcing rods projecting upward in ususual and well known manner as anchorage for posts, sub-posts and rails. Preferably the main posts 46 at the ends of the bridge and such intermediate points as are necessary or desired are also constructed.

If precast spindles are to be used these spindles are cast in suitable forms and allowed to set and cure. In their preferred form these spindles are cast with laterally projecting flanges 96 at their top ends whereby to provide means for supporting them when placed. Also they may be, and preferably are, provided with upwardly and downwardly extending reinforcing rods 9| and 92 projecting respectively from their upper and lower ends.

The outer side frame, including the form plate 32 for the side of the Wheel guard, the plate I9 for the side of the hand rail and plate 52 for intermediate sub-posts, is placed, but not finally positioned, between two of the end posts with the plates facing inward. The complementary frame for the inner side of the rail is then placed with the plates facing outward and is moved into position and secured and braced. It will be noted that the frame members 26 extend beyond the otherwise end of the frame and overlap the posts 46 whereby they may be, at least initially, of use in the positioning of the forms, that is they allow the outer frame to be initially braced against the outer side of the posts and prevent the inner frame from being pushed too far outward. Also they are of assistance in the alignment of the ends of the frame with respect to the posts.

a The outer frame is roughly positioned and aligned and the spindles are thendropped into place with the flanges 90 thereof resting on the 7 inwardly projecting portions ISA of the upper stringers. Ties 38 and 39 are then inserted and tightened up until the edges of the stringers l0 and I I lightly engage and align the spindles. The top ends of the spindles are now adjusted to secure uniform spacing and additional ties are placed one on each side of the spindle, such additional ties however not necessarily being utilized to clamp the frame together. The blocks 43 are placed on these ties and supported thereby between each and every spindle and on these blocks thin plates M are placed to provide a form for the underside of the concrete rail between the spindles. These thin plates M are usedin addition to the blocks in order that the blocks may be removed while leaving the concrete protected by the thin plates. Preferably the thin plates are in two parts so as to allow their later removal from the concrete surface without disturbing the same. After properly spacing the spindles, the ties connecting the top stringers are additionally tightened to grip the spindles more firmly. The lower ends of the spindles are now moved, if it be necessary, to bring the spindles into vertical position 'andthe ties connecting the lower stringers are tightened.

At the time the frames are brought into position the end plates for the sub-posts are placed and as the frames are brought together they are clamped there between. Prior to such clamping they are adjusted to a vertical position and where the panel formof the post is secured by bolts this also is adjusted so that its side edges may be vertical. The spindles having been properly positioned and vertically aligned, and the panel plates similarly aligned, final tightening of the ties is made to clamp the upper and lower stringers against the spindles and the end plates of the sub-posts. In accomplishing this tightening minor inequalities in alignment occur which inequalities so far as the top rail is concerned, are now corrected by adjusting the screws 25 and 36 respectively until the side plates IQ for the upper rail are definitely straight and true. In tightening thestringers against the spindles, it

sometimes happens that the form plate 52 for the sub-post must be loosened to allow proper clamping against the spindles, or that they must be tightened tosecure proper gripping against the end plates of the post and suchadjustment may be accomplished by means of the adjusting bolts Where the spindles are to be cast integral with the top and bottom rails, the spindle cores are inserted between the side plates and clamping and aligning, accomplished as before.

It will 7 be understood that clamping of the stringers through the medium of the ties 38 and 39 may be accomplished by means of the wedges described,'or that such tightening maybe accomplished by other usual and well-known forms of tightening device.

The forms having been properly clamped and aligned concrete is poured into the bottom rail until the same is level with the top of the members 35 and is struck off around and between the spindles, concrete is also poured into the top of the forms to fill the top rail and thesub-posts. Concrete so placed is leveled off and the top finish of the rail accomplished as by means of a' strike board or screed Hill, which conforms to the desired shape of the top of the rail. Where the spindles are'cast integral with the rails all the concrete is poured into the forms from the top, the finishing of the top being similarly accomplished. In either event the guide for the strike board is ordinarily the top edge of the side forms ill or the reinforcing angles 2! attached thereto. a

After pouring, the concrete is allowed to set in engagement, the slope given the top stringer provides sufiicient draft to allow such removal. Also since the top of the form is first pulled outward, the lower edges 53 of the sub-postpanels lift away and readily disengagefrom the concrete.

After removal of the side forms, where. the spindles are cast integral with the rails,.the cores remain in place and must be individually removed. To accomplish this the lower ends 15 of the cores are disengaged and the parts 1415 are swung inward to the positions 15X shown. dotted in Fig. 11. The core sides are thus freed to move inward and be moved downward to complete the release of the core and allow its lateral removal. 20

After stripping, the railings and spindles are finished in usual or desired manner. 7

It will be understood that while the form plates 32 for the lower rail have been shown directly attached to the lower portion of the studs, they 25 may be provided with brackets corresponding to the brackets 23 of the upper plates I9 and with similar adjusting means whereby alignment of the lower plates 'relative'to the frame structure studs and having its lower edge contacting said'io second stringer, and means for aligning said 'ad- 7 justable form plate with reference to the align-' ment of said frame. j I V 2. In a form for concrete, a form member comprising a frame which includes vertically disposed at studs, a longitudinally disposed stringer, a longitudinally disposed sill member and a longitudinal plate vertically disposed, rigidly attached-to said studs, a second stringer disposed thereabove and adjustably attached to said studs, a longitudinal form plate, vertically disposed, and adjustably attached to said studs; and means for aligning said adjustable form plate with reference to the alignment of said frame.

3. In aformfor concrete, a form member com- 5 5 prising a frame which includes vertically disposed studs, a longitudinally disposed stringer, a longitudinally disposed cap member, and a longitu dinal plate vertically'disposed, rigidly attachedto said studs, a second stringer disposed thereabovellfl and adjustably attachedto said studs, and a longitudinal form platavertically disposed, and adjustably attached to. said studs, and meansfor aligning said formplate with reference to the alignment of'said frame. I 4. In a form for concret'e, a form memberineluding vertically disposed studs, a pair of longitudinally disposed stringers and longitudinally disposed formplates all attached, to one face of said studs, a postgform'plate disposed below ,the 70 upper'of said stringers and depending below the l other thereof, said plate having an outwardly bent portion underlying said top stringer, and at r its lower endan outwardly bent portion-overlying I the lower of said form platesjrand means tor-m at),

justing the positioning of said post-form plate relatively to said stringers and plates.

5. In a form for concrete, a frame including a plurality of vertically disposed studs, and a plurality of horizontally disposed stiffening members coextensive in length with said form, integrally secured to said studs, a stringer adjustably secured to the face side of said studs, intermediate their height, form plates coextensive in length with said frame, and lying along the face sides of said studs, the lower of said plates being integrally attached to said studs at their lower ends, and the upper of said plates being adjustably attached to the upper end of said studs, and means for adjusting the alignment of said upper pla relative to the alignment of said frame.

6. A form for concrete, including an opposed pair of frames, means for holding said frames apart, and means for tieing same in such position; each of said frames including vertically disposed studs, a longitudinal stringer and a vertically disposed plate extending longitudinally of said frame and rigidly attached to the inner face of said studs, adjacent the lower ends thereof, a second stringer spaced above said first stringer, and adjustably attached to said studs, a second plate extending longitudinally of said frame and adjustably attached to said studs, said plate having its lower edge contacting said stringer, and means for aligning said second plate with reference to the alignment of said frame.

'7. A form for concrete, including a pair of form members and means for securing said form members against lateral separation; each of said form members comprising a form, including a plurality of vertically disposed studs, and a plurality of horizontally disposed stiffening members, coextensive in length with said form, rigidly secured to said studs, a stringer adjustably secured to the face side of said studs, intermediate their height, form plates coextensive in length with said frame, and lying along the face sides of said studs, the lower of said plates being rigidly attached to said studs at their lower ends, and the upper of said plates contacting the upper surface of said stringer and being adjustably attached to the upper .end of said studs, and means for adjusting the alignment of said upper plate relative to the alignment of said frame.

8. A form for concrete, including a pair of form members and means for securing said members against separation; each of said members including vertically disposed studs, a pair of longitudinally disposed, spaced, stringers and longitudinally disposed, spaced, form plates all attached to one face of said studs, a post-form plate disposed below the upper of said stringers and depending below the other thereof, said plate having at its upper end an outwardly bent portion underlying said top stringer, and at its lower end, an outwardly bent portion overlying the lower of said form plates, means for ad- 5 justing the positioning of said post-form plate relatively to said stringers and plates, removable end plates disposed between said post-form plates, said form plates being substantially vertical, and means for adjusting said end plates to 10 vertical position.

9. A form for concrete, including a pair of form members and. means for secutrmgi said members against separation; each of said members including vertically disposed studs, a pair of 15 longitudinally disposed, spaced, stringers and longitudinally disposed, spaced, form plates all attached to one face of said studs, a post-form plate disposed below the upper of said stringers and depending below the other thereof, said 20 plate having at its upper end an outwardly bent portion underlying said top stringer, and at its lower end, an outwardly bent portion overlying the lower of said form plates, means for adjusting the positioning of said post-form plate rela- 25 tively to said stringers and plates and removable end plates disposed between said post-form plates, said form plates being substantially vertical.

10. A form for concrete guards for bridges or the like, which guards include upper and lower 30 rails and precast spindles, extending between and incorporated therewith, said form including a pair of form members and means for securing said members against lateral separation; each of said form members having a plurality of ver- 35 tically disposed studs, horizontally disposed stiff-- ening members coextensive in length with said form, secured to said studs, said members including'a pair of angle irons spaced apart each disposed with one leg vertical and lying along the inner faces of said studs and one leg horizontal and extending inward, whereby to contact spindles spaced therebetween, the vertical legs of said angles being slotted, side form plates coextensive in length with said form lying along the 4,5

' inner face of said studs and secured to said studs to accomplish respectively the upper and lower rail side forms; said securing means comprising ties insertable through correspondingly disposed slots of opposite ones of said angles, and means 5 engaging said ties and abutting the outer sides of said angles; and blocks disposable between said spindles extending between the horizontal legs of the upper pair of said angles and supported by said ties, completing the form for the 55 upper of said rails.

LAWRENCE T. THORN. 

